Search results for: adaptive machining

Authors: Azhar Equbal, Anoop Kumar Sood, M. Asif Equbal, M. Israr Equbal

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In the present work response surface methodology (RSM) based central composite design (CCD) is used for analyzing the electrical discharge machining (EDM) process. For experimentation, mild steel is selected as work piece and copper is used as electrode. Three machining parameters namely current (I), spark on time (T_on) and spark off time (T_off) are selected as the input variables. The output or response chosen is material removal rate (MRR) which is to be maximized. To reduce the number of runs face centered central composite design (FCCCD) was used. ANOVA was used to determine the significance of parameter and interactions. The suitability of model is tested using Anderson darling (AD) plot. The results conclude that different parameters considered i.e. current, pulse on and pulse off time; all have dominant effect on the MRR. At last, the optimized parameter setting for maximizing MRR is found through main effect plot analysis.

Keywords: EDM, electrode, MRR, RSM, ANOVA

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Authors: Dong Sang Yoo

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We consider nonlinear uncertain systems such that a priori information of the uncertainties is not available. For such systems, we assume that the upper bound of the uncertainties is represented as a Fredholm integral equation of the first kind and we propose an adaptation law that is capable of estimating the upper bound and design a continuous robust control which renders nonlinear uncertain systems ultimately bounded.

Keywords: adaptive control, estimation, Fredholm integral, uncertain system

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Authors: Massra M. Sabeima, Myriam lamolle, Mohamedade Farouk Nanne

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Adapting the learning resources of an e-learning system to the characteristics of the learners is an important aspect to consider when designing an adaptive e-learning system. However, this adaptation is not a simple process; it requires the extraction, analysis, and modeling of user information. This implies a good representation of the user's profile, which is the backbone of the adaptation process. Moreover, during the e-learning process, collaboration with similar users (same geographic province or knowledge context) is important. Productive collaboration motivates users to continue or not abandon the course and increases the assimilation of learning objects. The contribution of this work is the following: we propose an adaptive e-learning semantic platform to recommend learning resources to learners, using ontology to model the user profile and the course content, furthermore an implementation of a multi-agent system able to progressively generate the learning graph (taking into account the user's progress, and the changes that occur) for each user during the learning process, and to synchronize the users who collaborate on a learning object.

Keywords: adaptative learning, collaboration, multi-agent, ontology

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Authors: Oğuzhan Hasançebi, Saeid Kazemzadeh Azad

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Keywords: structural design optimization, optimal sizing, metaheuristics, self-adaptive step-size search, steel trusses, steel frames

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Authors: Yong-Jun Kim, Jae-Hyun Ro, Chang-Bin Ha, Hyoung-Kyu Song

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This paper proposes the cooperative transmission scheme with pre-coding because the cellular communication requires high reliability. The cooperative transmission scheme uses pre-coding method with limited feedback information among small cells. Particularly, the proposed scheme has adaptive mode according to the position of mobile station. Thus, demand of recent wireless communication is resolved by this scheme. From the simulation results, the proposed scheme has better performance compared to the conventional scheme in the cellular network.

Keywords: CDD, cellular network, pre-coding, SPC

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Authors: Nurul Na'imy Wan, Mohamad Sazali Said, Jaharah Ab. Ghani, Mohd Asri Selamat

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This paper presents the surface roughness of the Aluminium silicon alloy (AlSi) matrix composite which has been reinforced with aluminium nitride (AlN), with three types of carbide inserts. Experiments were conducted at various cutting speeds, feed rates, and depths of cut, according to the Taguchi method, using a standard orthogonal array L27 (34). The signal-to-noise (S/N) ratio and analysis of variance are applied to study the characteristic performance of machining parameters in measuring the surface roughness during the milling operation. The analysis of results, using the Taguchi method concluded that a combination of low feed rate, medium depth of cut, low cutting speed, and insert TiB2 give a better value of surface roughness. From Taguchi method, it was found that cutting speed of 230m/min, feed rate of 0.4 mm/tooth, depth of cut of 0.5mm and type of insert of TiB2 were the optimal machining parameters that gave the optimal value of surface roughness.

Keywords: AlSi/AlN Metal Matrix Composite (MMC), surface roughness, Taguchi method

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Authors: Prafulla Kumar Choubey, Krishna Kishor Jha, S. B. Vaisakh Punnekkattu Chirayil

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In Graphics-display subsystem, frame buffers are shared between producer i.e. content rendering and consumer i.e. display. If a common buffer is operated by both producer and consumer simultaneously, their processing rates mismatch can cause tearing effect in displayed content. Therefore, Android OS employs triple buffered system, taking in to account an additional composition stage. Three stages-rendering, composition and display refresh, operate synchronously on three different buffers, which is achieved by using vsync pulses. This synchronization, however, brings in to the pipeline an additional latency of up to 26ms. The present study details about the existing synchronization mechanism of android graphics-display pipeline and discusses a new adaptive architecture which reduces the wait time to 5ms-16ms in all the use-cases. The proposed method uses two adaptive software vsyncs (PLL) for achieving the same result.

Keywords: Android graphics system, vertical synchronization, atrace, adaptive system

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Authors: Rajat Raj, Rohini S. Hallikar

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The ever-increasing integration of renewable energy sources in the power grid necessitates the development of efficient and reliable microgrid systems. Photovoltaic (PV) systems coupled with energy storage technologies, such as batteries, offer promising solutions for sustainable and resilient power generation. This paper proposes an adaptive power control topology for a PV-battery microgrid system, aiming to optimize the utilization of available solar energy and enhance the overall system performance. In order to provide a smooth transition between the OFF-GRID and ON-GRID modes of operation with proportionate power sharing, a self-adaptive control method for a microgrid is proposed. Three different modes of operation are discussed in this paper, i.e., GRID connected, the transition between Grid-connected and Islanded State, and changing the irradiance of PVs and doing the transitioning. The simulation results show total harmonic distortion to be 0.08, 1.43 and 2.17 for distribution generation-1 and 4.22,3.92 and 2.10 for distribution generation-2 in the three modes, respectively which helps to maintain good power quality. The simulation results demonstrate the superiority of the adaptive power control topology in terms of maximizing renewable energy utilization, improving system stability and ensuring a seamless transition between grid-connected and islanded modes.

Keywords: islanded modes, microgrids, photo voltaic, total harmonic distortion

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Authors: Moaz H. Ali, Ahmed H. Al-Saadi

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Most of the materials used in the industry of aero-engine components generally consist of titanium alloys. Advanced materials, because of their excellent combination of high specific strength, lightweight, and general corrosion resistance. In fact, chemical wear resistance of aero-engine alloy provide a serious challenge for cutting tool material during the machining process. The reduction in cutting temperature distributions leads to an increase in tool life and a decrease in wear rate. Hence, the chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The result of low thermal conductivity and diffusivity of this alloy in the concentration of high temperatures at the tool-work-piece and tool-chip interface. Consequently, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. Otherwise, the result will be accelerating tool wear, increasing manufacturing cost and time consuming.

Keywords: machinability, titanium alloy (ti-6al-4v), chip formation, milling process

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Authors: G. Rajyalakhmi, C. Karthik, Gerson Desouza, Rimmie Duraisamy

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In this present work, metal matrix composites with combination of aluminium with (Sic/Al2O3) were fabricated using stir casting technique. The objective of the present work is to optimize the process parameters of Wire Electric Discharge Machining (WEDM) composites. Pulse ON Time, Pulse OFF Time, wire feed and sensitivity are considered as input process parameters with responses Material Removal Rate (MRR), Surface Roughness (SR) for optimization of WEDM process. Taguchi L18 Orthogonal Array (OA) is used for experimentation. Grey Relational Analysis (GRA) is coupled with Taguchi technique for multiple process parameters optimization. ANOVA (Analysis of Variance) is used for finding the impact of process parameters individually. Finally confirmation experiments were carried out to validate the predicted results.

Keywords: parametric optimization, particulate reinforced metal matrix composites, Taguchi-grey relational analysis, WEDM

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Authors: Ahmadur Rahman, Showkat Ahmad Lone, Ariful Islam

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In this article, we have estimated the parameters for the failure times of units based on the sampling technique adaptive type-I progressive hybrid censoring under the step-stress partially accelerated life tests for competing risk. The failure times of the units are assumed to follow an exponential distribution. Maximum likelihood estimation technique is used to estimate the unknown parameters of the distribution and tampered coefficient. Confidence interval also obtained for the parameters. A simulation study is performed by using Monte Carlo Simulation method to check the authenticity of the model and its assumptions.

Keywords: adaptive type-I hybrid progressive censoring, competing risks, exponential distribution, simulation, step-stress partially accelerated life tests

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Authors: Alaa Abdullah Altaee

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This paper presents an adaptive decision feedback equalizer (ADFE) for multi-Gbps serial links utilizing a fix-step error signal extracted from cross-points of received data symbols. The extracted signal is generated based on violation of received data symbols with minimum detection requirements at the clock and data recovery (CDR) stage. The iterations of the adaptation process search for the optimum feedback tap coefficients to maximize the data eye-opening and minimize the adaptation convergence time. The effectiveness of the proposed architecture is validated using the simulation results of a serial link designed in an IBM 130 nm 1.2V CMOS technology. The data link with variable channel lengths is analyzed using Spectre from Cadence Design Systems with BSIM4 device models.

Keywords: adaptive DFE, CMOS equalizer, error detection, serial links, timing jitter, wire-line communication

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Authors: Mesfer Al Duhayyim, Paul Newbury

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This paper proposes an effective adaptive e-learning system that uses a coloured concept map to show the learner's knowledge level for each concept in the chosen subject area. A Fuzzy logic system is used to evaluate the learner's knowledge level for each concept in the domain, and produce a ranked concept list of learning materials to address weaknesses in the learner’s understanding. This system obtains information on the learner's understanding of concepts by an initial pre-test before the system is used for learning and a post-test after using the learning system. A Fuzzy logic system is used to produce a weighted concept map during the learning process. The aim of this research is to prove that such a proposed novel adapted e-learning system will enhance learner's performance and understanding. In addition, this research aims to increase participants' overall understanding of their learning level by providing a coloured concept map of understanding followed by a ranked concepts list of learning materials.

Keywords: adaptive e-learning system, coloured concept map, fuzzy logic, ranked concept list

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Authors: Negin Binesh, Mohammad Hossein Niksokhan, Amin Sarang

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Best Management Practices (BMPs) are considered as one of the most important structural adaptive measures to climate change and urban development challenges in recent decades. However, not every location is appropriate for applying BMPs in the watersheds. In this paper, location prioritization of two kinds of BMPs was done: Pourous pavement and Detention pond. West Flood-Diversion (WFD) catchment in northern parts of Tehran, Iran, was considered as the case study. The methodology includes integrating the results of Storm Water Management Model (SWMM) into Fuzzy Analytic Hierarchy Process (FAHP) method using Geographic Information System (GIS). The results indicate that mostly suburban areas of the watershed in northern parts are appropriate for applying detention basin, and downstream high-density urban areas are more suitable for using permeable pavement.

Keywords: adaptive measures, BMPs, location prioritization, urban flooding

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Authors: Hany Mohamed Abdu, Mohamed Hassan Gadallah, El-Giushi Mokhtar, Yehia Mahmoud Ismail

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Laser beam cutting is one nontraditional machining process. This paper optimizes the parameters of Laser beam cutting machining parameters of Stainless steel (316L) by considering the effect of input parameters viz. power, oxygen pressure, frequency and cutting speed. Statistical design of experiments are carried in three different levels and process responses such as 'Average kerf taper (Ta)' and 'Surface Roughness (Ra)' are measured accordingly. A quadratic mathematical model (RSM) for each of the responses is developed as a function of the process parameters. Responses predicted by the models (as per Taguchi’s L27 OA) are employed to search for an optimal parametric combination to achieve desired yield of the process. RSM models are developed for mean responses, S/N ratio, and standard deviation of responses. Optimization models are formulated as single objective problem subject to process constraints. Models are formulated based on Analysis of Variance (ANOVA) using MATLAB environment. Optimum solutions are compared with Taguchi Methodology results.

Keywords: optimization, laser cutting, robust design, kerf width, Taguchi method, RSM and DOE

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Authors: N. Scheidegger, A. Mueller

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Job preferences are a well-developed research field. Many studies analyze the preferences using simple ratings with a sample of university graduates. The current study analyzes the preferences with a mixed method approach of a qualitative preliminary study and adaptive conjoint-analysis. Preconditions of accepting job offers are clarified for professionals in the industrial sector. It could be shown that, e.g. wages above the average are critical and that career opportunities must be seen broader than merely a focus on formal personnel development programs. The results suggest that, to be effective with their recruitment efforts, employers must take into account key desirable job attributes of their target group.

Keywords: conjoint analysis, employer attractiveness, job preferences, personnel marketing

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Authors: Pornthep Rachnavy

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The purpose of this paper is twofold. First, we believe that there are a significant relationship between sculling angle and sculling style among adaptive rowing. Second, we introduce a methodology used for adaptive rowing, namely simulation, to identify effectiveness of adaptive rowing. For our study we simulate the arms only single scull of adaptive rowing. The method for rowing fastest under the 1000 meter was investigated by study sculling angle using the simulation modeling. A simulation model of a rowing system was developed using the Matlab software package base on equations of motion consist of many variation for moving the boat such as oars length, blade velocity and sculling style. The boat speed, power and energy consumption on the system were compute. This simulation modeling can predict the force acting on the boat. The optimum sculling angle was performing by computer simulation for compute the solution. Input to the model are sculling style of each rower and sculling angle. Outputs of the model are boat velocity at 1000 meter. The present study suggests that the optimum sculling angle exist depends on sculling styles. The optimum angle for blade entry and release with respect to the perpendicular through the pin of the first style is -57.00 and 22.0 degree. The optimum angle for blade entry and release with respect to the perpendicular through the pin of the second style is -57.00 and 22.0 degree. The optimum angle for blade entry and release with respect to the perpendicular through the pin of the third style is -51.57 and 28.65 degree. The optimum angle for blade entry and release with respect to the perpendicular through the pin of the fourth style is -45.84 and 34.38 degree. A theoretical simulation for rowing has been developed and presented. The results suggest that it may be advantageous for the rowers to select the sculling angles proper to sculling styles. The optimum sculling angles of the rower depends on the sculling styles made by each rower. The investigated of this paper can be concludes in three directions: 1;. There is the optimum sculling angle in arms only single scull of adaptive rowing. 2. The optimum sculling angles depend on the sculling styles. 3. Computer simulation of rowing can identify opportunities for improving rowing performance by utilizing the kinematic description of rowing. The freedom to explore alternatives in speed, thrust and timing with the computer simulation will provide the coach with a tool for systematic assessments of rowing technique In addition, the ability to use the computer to examine the very complex movements during rowing will help both the rower and the coach to conceptualize the components of movements that may have been previously unclear or even undefined.

Keywords: simulation, sculling, adaptive, rowing

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Authors: Kourosh Modarresi

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The Netflix problem has brought the topic of “Recommendation Systems” into the mainstream of computer science, mathematics, and statistics. Though much progress has been made, the available algorithms do not obtain satisfactory results. The success of these algorithms is rarely above 5%. This work is based on the belief that the main challenge is to come up with “scalable personalization” models. This paper uses an adaptive regularization of inverse singular value decomposition (SVD) that applies adaptive penalization on the singular vectors. The results show far better matching for recommender systems when compared to the ones from the state of the art models in the industry.

Keywords: convex optimization, LASSO, regression, recommender systems, singular value decomposition, low rank approximation

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Authors: Mubarak Alhajri

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This paper addresses certain inherent limitations of local priority hysteresis switching logic. Our main result establishes that under persistent excitation assumption, it is possible to relax constraints requiring strict positivity of local priority and hysteresis switching constants. Relaxing these constraints allows the adaptive system to reach optimality which implies the performance improvement. The unconstrained local priority hysteresis switching logic is examined and conditions for global convergence are derived.

Keywords: adaptive control, convergence, hysteresis constant, hysteresis switching

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Authors: Ju-Hong Lee, Ching-Wei Liao

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An adaptive array beamformer is designed for automatically preserving the desired signals while cancelling interference and noise. Providing robustness against model mismatches and tracking possible environment changes calls for robust adaptive beamforming techniques. The design criterion yields the well-known generalized sidelobe canceller (GSC) beamformer. In practice, the knowledge of the desired steering vector can be imprecise, which often occurs due to estimation errors in the DOA of the desired signal or imperfect array calibration. In these situations, the SOI is considered as interference, and the performance of the GSC beamformer is known to degrade. This undesired behavior results in a reduction of the array output signal-to-interference plus-noise-ratio (SINR). Therefore, it is worth developing robust techniques to deal with the problem due to local scattering environments. As to the implementation of adaptive beamforming, the required computational complexity is enormous when the array beamformer is equipped with massive antenna array sensors. To alleviate this difficulty, a generalized sidelobe canceller (GSC) with partially adaptivity for less adaptive degrees of freedom and faster adaptive response has been proposed in the literature. Unfortunately, it has been shown that the conventional GSC-based adaptive beamformers are usually very sensitive to the mismatch problems due to local scattering situations. In this paper, we present an effective GSC-based beamformer against the mismatch problems mentioned above. The proposed GSC-based array beamformer adaptively estimates the actual direction of the desired signal by using the presumed steering vector and the received array data snapshots. We utilize the predefined steering vector and a presumed angle tolerance range to carry out the required estimation for obtaining an appropriate steering vector. A matrix associated with the direction vector of signal sources is first created. Then projection matrices related to the matrix are generated and are utilized to iteratively estimate the actual direction vector of the desired signal. As a result, the quiescent weight vector and the required signal blocking matrix required for performing adaptive beamforming can be easily found. By utilizing the proposed GSC-based beamformer, we find that the performance degradation due to the considered local scattering environments can be effectively mitigated. To further enhance the beamforming performance, a signal subspace projection matrix is also introduced into the proposed GSC-based beamformer. Several computer simulation examples show that the proposed GSC-based beamformer outperforms the existing robust techniques.

Keywords: adaptive antenna beamforming, local scattering, signal blocking, steering mismatch

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Authors: Wallyson Thomas, Zsombor Fulop, Attila Szilagyi

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Impact dampers are mainly used in the metal-mechanical industry in operations that generate too much vibration in the machining system. Internal turning processes become unstable during the machining of deep holes, in which the tool holder is used with long overhangs (high length-to-diameter ratios). The devices coupled with active dampers, are expensive and require the use of advanced electronics. On the other hand, passive impact dampers (PID – Particle Impact Dampers) are cheaper alternatives that are easier to adapt to the machine’s fixation system, once that, in this last case, a cavity filled with particles is simply added to the structure of the tool holder. The cavity dimensions and the diameter of the spheres are pre-determined. Thus, when passive dampers are employed during the machining process, the vibration is transferred from the tip of the tool to the structure of the boring bar, where it is absorbed by the fixation system. This work proposes to compare the behaviors of a conventional solid boring bar and a boring bar with a passive impact damper in turning while using the highest possible L/D (length-to-diameter ratio) of the tool and an Easy Fix fixation system (also called: Split Bushing Holding System). It is also intended to optimize the impact absorption parameters, as the filling percentage of the cavity and the diameter of the spheres. The test specimens were made of hardened material and machined in a Computer Numerical Control (CNC) lathe. The laboratory tests showed that when the cavity of the boring bar is totally filled with minimally spaced spheres of the largest diameter, the gain in absorption allowed of obtaining, with an L/D equal to 6, the same surface roughness obtained when using the solid boring bar with an L/D equal to 3.4. The use of the passive particle impact damper resulted in, therefore, increased static stiffness and reduced deflexion of the tool.

Keywords: active damper, fixation system, hardened material, passive damper

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Authors: Shilpa Kumari, Ramakumar Jayachandran

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Machining of aluminium extrusion profiles in the automotive industry has gained much interest in the last decade, particularly due to the higher utilization of aluminum profiles and the weight reduction benefits it brings. Milling is the most common material removal process, where the rotary milling cutter is moved against a workpiece. The physical contact of the milling cutter to the workpiece increases the friction between them, thereby affecting the longevity of the milling tool and also the surface finish of the workpiece. To minimise this issue, the milling process uses cutting fluids or emulsions; however, the use of emulsion in the process has a negative impact on the environment ( such as consumption of water, oils and the used emulsion needs to be treated before disposal) and also on the personal ( may cause respiratory problems, exposure to microbial toxins generated by bacteria in the emulsions on prolonged use) working close to the process. Furthermore, the workpiece also needs to be cleaned after the milling process, which is not adding value to the process, and the cleaning also disperses mist of emulsion in the working environment. Hydro Extrusion is committed to improving the performance of sustainability from its operations, and with the negative impact of using emulsion in the milling process, a new innovative process- Dry Milling was developed to minimise the impact the cutting fluid brings. In this paper, the authors present one application of dry milling in the machining of tensile specimens in the laboratory. Dry milling is an innovative milling process without the use of any cooling/lubrication and has several advantages. Several million tensile tests are carried out in extrusion laboratories worldwide with the wet milling process. The machining of tensile specimens has a significant impact on the reliability of test results. The paper presents the results for different 6xxx alloys with different wall thicknesses of the specimens, which were machined by both dry and wet milling processes. For both different 6xxx alloys and different wall thicknesses, mechanical properties were similar for samples milled using dry and wet milling. Several tensile specimens were prepared using both dry and wet milling to compare the results, and the outcome showed the dry milling process does not affect the reliability of tensile test results.

Keywords: dry milling, tensile testing, wet milling, 6xxx alloy

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Authors: Henni Mansour Abdelwaheb

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This study discusses the design of a bounded position/force feedback controller developed to ensure position and force tracking for bilateral teleoperation arms operating with variable delay, and actuator saturation. Also, an adaptive robust Radial Basis Function (RBF) neural network is used to estimate the environment torque. The parameters of the environment torque are then sent from the slave site to the master site as a non-power signal to avoid passivity problems. Moreover, a nonlinear function is applied to each controller term as a smooth saturation function, providing a bounded control signal and preserving the system’s actuators. Lastly, the Lyapunov approach demonstrates the global stability of the controlled system, and numerical experiment results further confirm the validity of the presented strategy.

Keywords: teleoperation manipulators system, time-varying delay, actuator saturation, adaptive robust rbf neural network approximation, uncertainties

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Authors: Balkar Singh, Gurpreet Singh, Vivek Aggarwal, Sehijpal Singh

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The present research focused to improve the machinability of Hastelloy C-276 at different machining speeds such as 31, 55, and 79 m/min. The use of CO2 gas and Minimum quantity lubrication (MQL) was applied as coolant and lubrication purposes to enhance the machinability of the superalloy. The output in the form of surface roughness (S.R) and heat generation was monitored under dry, MQL, and MQL-CO2-cooled conditions. The Design of the Experiment was prepared using MINITAB software utilizing Taguchi L-27 orthogonal arrays followed by ANOVA analysis for finding the impact of input variables on output responses. At different speeds and lubrication conditions, different behavioral patterns for Surface Roughness and the temperature was observed. ANOVA analysis depicted that the cooling environment impacted the S.R. majorly (50%) followed by cutting speed (29.84%), feed rate (5.09%), and least through depth of cut (4.95%). On the other side, the temperature was greatly influenced by cutting speed (69.12%), Cryo-MQL (8.09%), feed rate (7.59%), and depth of cut (6.20%). Experimental results revealed that Cryo-MQL cooling enhanced the Surface roughness by 12% compared to MQL condition.

Keywords: Hastelloy C-276, minimum quantity lubrication, olive oil, cryogenic Cooling (CO2)

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Authors: Rami Faraj, Cezary Graczykowski, Błażej Popławski, Grzegorz Mikułowski, Rafał Wiszowaty

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Progress in the field of sensors, electronics and computing results in more and more often applications of adaptive techniques for dynamic response mitigation. When it comes to systems excited with mechanical impacts, the control system has to take into account the significant limitations of actuators responsible for system adaptation. The paper provides a comprehensive discussion of the problem of appropriate design and implementation of adaptation techniques and mechanisms. Two case studies are presented in order to compare completely different adaptation schemes. The first example concerns a double-chamber pneumatic shock absorber with a fast piezo-electric valve and parameters corresponding to the suspension of a small unmanned aerial vehicle, whereas the second considered system is a safety air cushion applied for evacuation of people from heights during a fire. For both systems, it is possible to ensure adaptive performance, but a realization of the system’s adaptation is completely different. The reason for this is technical limitations corresponding to specific types of shock-absorbing devices and their parameters. Impact mitigation using a pneumatic shock absorber corresponds to much higher pressures and small mass flow rates, which can be achieved with minimal change of valve opening. In turn, mass flow rates in safety air cushions relate to gas release areas counted in thousands of sq. cm. Because of these facts, both shock-absorbing systems are controlled based on completely different approaches. Pneumatic shock-absorber takes advantage of real-time control with valve opening recalculated at least every millisecond. In contrast, safety air cushion is controlled using the semi-passive technique, where adaptation is provided using prediction of the entire impact mitigation process. Similarities of both approaches, including applied models, algorithms and equipment, are discussed. The entire study is supported by numerical simulations and experimental tests, which prove the effectiveness of both adaptive impact mitigation techniques.

Keywords: adaptive control, adaptive system, impact mitigation, pneumatic system, shock-absorber

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Authors: Jhe-Hao Huang, Kun-Da Wu, Wei-Cheng Shih, Jui-Pin Hung

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This study presented the investigation on the dynamic characteristics of a spindle tool system by experimental and finite element modeling approaches. As well known facts, the machining stability is greatly determined by the dynamic characteristics of the spindle tool system. Therefore, understanding the factors affecting dynamic behavior of a spindle tooling system is a prerequisite in dominating the final machining performance of machine tool system. To this purpose, a physical spindle unit was employed to assess the dynamic characteristics by vibration tests. Then, a three-dimensional finite element model of a high-speed spindle system integrated with tool holder was created to simulate the dynamic behaviors. For modeling the angular contact bearings, a series of spring elements were introduced between the inner and outer rings. The spring constant can be represented by the contact stiffness of the rolling bearing based on Hertz theory. The interface characteristic between spindle nose and tool holder taper can be quantified from the comparison of the measurements and predictions. According to the results obtained from experiments and finite element predictions, the vibration behavior of the spindle is dominated by the bending deformation of the spindle shaft in different modes, which is further determined by the stiffness of the bearings in spindle housing. Also, the spindle unit with tool holder shows a different dynamic behavior from that of spindle without tool holder. This indicates the interface property between tool holder and spindle nose plays an dominance on the dynamic characteristics the spindle tool system. Overall, the dynamic behaviors the spindle with and without tool holder can be successfully investigated through the finite element model proposed in this study. The prediction accuracy is determined by the modeling of the rolling interface of ball bearings in spindles and the interface characteristics between tool holder and spindle nose. Besides, identifications of the interface characteristics of a ball bearing and spindle tool holder are important for the refinement of the spindle tooling system to achieve the optimum machining performance.

Keywords: contact stiffness, dynamic characteristics, spindle, tool holder interface

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Authors: Bruno S. Soria, Mauricio R. Policena, Andre J. Souza

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The state of the cutting tool is an important factor to consider during machining to achieve a good surface quality. The vibration generated during material cutting can also directly affect the surface quality and life of the cutting tool. In this work, the effect of mechanical broken failure (MBF) on carbide insert tools during face milling of AISI 304 stainless steel was evaluated using three levels of feed rate and two spindle speeds for each tool condition: three carbide inserts have perfect geometry, and three other carbide inserts have MBF. The axial and radial depths remained constant. The cutting forces were determined through a sensory system that consists of a piezoelectric dynamometer and data acquisition system. Discrete Wavelet Transform was used to separate the static part of the signals of force and vibration. The roughness of the machined surface was analyzed for each machining condition. The MBF of the tool increased the intensity and force of vibration and worsened the roughness factors.

Keywords: face milling, stainless steel, tool condition monitoring, wavelet discrete transform

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Authors: Ricardo Torcato, Helder Morais

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The manufacture of crystal glass parts is based on obtaining the rough geometry by blowing and/or injection, generally followed by a set of manual finishing operations using cutting and grinding tools. The forming techniques used do not allow the obtainment, with repeatability, of parts with complex shapes and the finishing operations use intensive specialized labor resulting in high cycle times and production costs. This work aims to explore the digital manufacture of crystal glass parts by investigating new subtractive techniques for the automated, flexible finishing of these parts. Finishing operations are essential to respond to customer demands in terms of crystal feel and shine. It is intended to investigate the applicability of different computerized finishing technologies, namely milling and grinding in a CNC machining center with or without ultrasonic assistance, to crystal processing. Research in the field of grinding hard and brittle materials, despite not being extensive, has increased in recent years, and scientific knowledge about the machinability of crystal glass is still very limited. However, it can be said that the unique properties of glass, such as high hardness and very low toughness, make any glass machining technology a very challenging process. This work will measure the performance improvement brought about by the use of ultrasound compared to conventional crystal grinding. This presentation is focused on the mechanical characterization and analysis of the cutting forces in CNC machining of superior crystal glass (Pb ≥ 30%). For the mechanical characterization, the Vickers hardness test provides an estimate of the material hardness (Hv) and the fracture toughness based on cracks that appear in the indentation. Mechanical impulse excitation test estimates the Young’s Modulus, shear modulus and Poisson ratio of the material. For the cutting forces, it a dynamometer was used to measure the forces in the face grinding process. The tests were made based on the Taguchi method to correlate the input parameters (feed rate, tool rotation speed and depth of cut) with the output parameters (surface roughness and cutting forces) to optimize the process (better roughness using the cutting forces that do not compromise the material structure and the tool life) using ANOVA. This study was conducted for conventional grinding and for the ultrasonic grinding process with the same cutting tools. It was possible to determine the optimum cutting parameters for minimum cutting forces and for minimum surface roughness in both grinding processes. Ultrasonic-assisted grinding provides a better surface roughness than conventional grinding.

Keywords: CNC machining, crystal glass, cutting forces, hardness

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Authors: C. Brecher, M. Fey, F. Du Bois-Reymond, S. Neus

Abstract:

Additive manufacturing has emerged into a fast-growing section within the manufacturing technologies. Established machine tool manufacturers, such as DMG MORI, recently presented machine tools combining milling and laser welding. By this, machine tools can realize a higher degree of flexibility and a shorter production time. Still there are challenges that have to be accounted for in terms of maintaining the necessary machining accuracy - especially due to thermal effects arising through the use of high power laser processing units. To study the thermal behavior of laser-integrated machine tools, it is essential to analyze and simulate the thermal behavior of machine components, individual and assembled. This information will help to design a geometrically stable machine tool under the influence of high power laser processes. This paper presents an approach to decrease the loss of machining precision due to thermal impacts. Real effects of laser machining processes are considered and thus enable an optimized design of the machine tool, respective its components, in the early design phase. Core element of this approach is a matched FEM model considering all relevant variables arising, e.g. laser power, angle of laser beam, reflective coefficients and heat transfer coefficient. Hence, a systematic approach to obtain this matched FEM model is essential. Indicating the thermal behavior of structural components as well as predicting the laser beam path, to determine the relevant beam intensity on the structural components, there are the two constituent aspects of the method. To match the model both aspects of the method have to be combined and verified empirically. In this context, an essential machine component of a five axis machine tool, the turn-swivel table, serves as the demonstration object for the verification process. Therefore, a turn-swivel table test bench as well as an experimental set-up to measure the beam propagation were developed and are described in the paper. In addition to the empirical investigation, a simulative approach of the described types of experimental examination is presented. Concluding, it is shown that the method and a good understanding of the two core aspects, the thermo-elastic machine behavior and the laser beam path, as well as their combination helps designers to minimize the loss of precision in the early stages of the design phase.

Keywords: additive manufacturing, laser beam machining, machine tool, thermal effects

Procedia PDF Downloads 243

Authors: Hatim Laalej, Jon Stammers

Abstract:

In machining, monitoring of tool wear is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Currently, the task of monitoring the wear on the cutting tool is carried out by the operator who performs manual inspections of the cutting tool, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from loss of productivity. The cutting tool consumable costs may also be higher than necessary when tools are changed before the end of their useful life. Furthermore, damage can be caused to the workpiece when tools are not changed soon enough leading to a significant increase in the costs of manufacturing. The present study is concerned with the development of break sensor printed on the flank surface of poly-crystalline diamond (PCD) cutting to perform on-line condition monitoring of the cutting tool used to machine Titanium Ti-6al-4v bar. The results clearly show that there is a strong correlation between the break sensor measurements and the amount of wear in the cutting tool. These findings are significant in that they help the user/operator of the machine tool to determine the condition of the cutting tool without the need of performing manual inspection, thereby reducing the manufacturing costs such as the machine down time.

Keywords: machining, manufacturing, tool wear, signal processing

Procedia PDF Downloads 211